Fatigue life prediction based on an equivalent initial flaw size approach and a
new normalized fatigue crack growth model

J.A.F.O. Correia, S. Balsón, A.M.P. De Jesus, A.F. Canteli, P.M.G.P.

Moreira, Paulo J. Tavares

PII: S1350-6307(16)30126-1
DOI: doi: 10.1016/j.engfailanal.2016.04.003
Reference: EFA 2857

To appear in:

Received date: 30 November 2015

Revised date: 23 March 2016
Accepted date: 1 April 2016

Please cite this article as: , Fatigue life prediction based on an equivalent initial
flaw size approach and a new normalized fatigue crack growth model, (2016), doi:
10.1016/j.engfailanal.2016.04.003

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FATIGUE LIFE PREDICTION BASED ON AN EQUIVALENT INITIAL FLAW SIZE

APPROACH AND A NEW NORMALIZED FATIGUE CRACK GROWTH MODEL

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J.A.F.O. Correia1*, S. Balsón2, A.M.P. De Jesus1, A.F. Canteli2,

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P.M.G.P. Moreira1, Paulo J. Tavares1

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1
INEGI, Faculty of Engineering, University of Porto,

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Rua Dr. Roberto Frias, Campus FEUP, 4200-465 Porto, Portugal.

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Department of Construction and Manufacturing Engineering, University of Oviedo,
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Campus de Viesques, 33203 Gijón, Spain.

*Corresponding author: jacorreia@inegi.up.pt

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ABSTRACT

A general procedure for fatigue life prediction of structural details based on Fracture

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Mechanics approach is presented in this paper, taking advantage of the new normalized fatigue
crack growth model proposed by Castillo et al., here denoted as CCS model. An extension to

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the CCS model is proposed by adopting the cyclic J-integral range instead of the stress intensity

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factor range as reference parameter. This enables the generalized elastoplastic conditions
resulting for the cracked geometry of the structural detail to be considered by means of the

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cyclic J-integral values obtained from a finite element analysis, for different loading levels and
crack lengths. As a practical application, the proposed approach is applied to a notched plate
made of P355NL1 steel, using the equivalent initial flaw size (EIFS) concept. Fatigue crack
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growth data for CT specimens from the literature is evaluated to estimate the modified CCS
crack growth model parameters. The predicted fatigue propagation lifetime prediction is
compared with the results and, finally, the goodness of the predictions is analysed and
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deviations discussed.
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KEYWORDS: Fatigue; Fracture Mechanics; Crack Propagation; Fatigue Life Prediction; EIFS
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1. INTRODUCTION

Fatigue life evaluation of structural details may be carried out based on global S-N approaches

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[1], local approaches, such as strain-life and stress-life models [2,3], and Fracture Mechanics
based fatigue approaches [4]. The global S-N approaches are supported by experimental results

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directly relating a global definition of stress range, Δσ, with total number of cycles to failure,

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Nf. The local approaches are associated with local failure modes (e.g. crack initiation) and
could be described by strain-life or stress-life relations, where strains and stresses are evaluated

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at a local hot spot. Fatigue crack initiation, despite not consensual, may be postulated as a crack
of 0.25 mm depth (macroscopic crack).
Fatigue approaches based on Fracture Mechanics principles, are supported by fatigue crack
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growth models which are used to predict the crack propagation from an initial crack size, ai, to
final crack size, af, the latter leading to the fracture of the structural detail or mechanical
component [5,6].
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The local approaches (e.g. strain-life) combined with the Fracture Mechanics constitutes an
integrated approach that allows the prediction of both fatigue crack initiation and propagation
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of structural details [7,8]. Another possibility for the fatigue life prediction is based on a unified
local approach which, using the elastoplastic stress–strain histories at the crack tip region and
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strain-life relations, fatigue crack growth process is computed by successive crack increments
assumed as crack re-initiations occurring over elementary material blocks [9-14].
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The Fracture Mechanics based fatigue approaches could also be used to predict the whole
fatigue life of structural details or mechanical details, using the equivalent initial flaw size
(EIFS) concept [5,6,15]. This approach postulates that materials have intrinsic defects that act
like initial cracks concerning a fatigue prediction model. This EIFS is usually lower than the
crack initiation concept of the local/Fracture Mechanics integrated approaches for the global
fatigue life. Only for some details like welded joints the two concepts may be coincident, since
the macroscopic crack initiation may be disregarded. In the perspective of the application of the
Fracture Mechanics based fatigue approaches with the EIFS, the applicability of K-based
Linear Elastic Facture Mechanics may be not appropriate due to the smaller size of the cracks
with respect to the plastic zone ahead the crack tip. Therefore, in these approaches the use of
the J-Integral concept is preferable with respect to the stress intensity factor. Also, the fatigue
crack propagation law should cover of the propagation regimes from near threshold fatigue
crack propagation until the final fast crack propagation.

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In this paper, it is proposed a general procedure for fatigue life prediction of notched details,
based on Fracture Mechanics and EIFS concept, supported by the cyclic J-integral and the
recent fatigue crack growth model, proposed by Castillo-Canteli-Siegele (CCS) [16,17]. The

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proposed procedure is applied to the fatigue life evaluation of a rectangular notched plate made
of P355NL1 steel. Fatigue crack growth data was obtained for stress R-ratios, using CT

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specimens. This data was used to estimate the parameters of the CCS crack growth model that

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was generalized for elastoplastic crack propagation conditions using the cyclic J-integral. The
fatigue life of the notched detail is computed and compared with S-N data available for that

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detail [18]. MA
2. FATIGUE LIFE EVALUATION BASED ON FRACTURE MECHANICS

Fatigue life evaluation based on Fracture Mechanics of notched details is supported by fatigue
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crack growth laws of the materials which are typically based on the stress intensity factor
range, ΔK, or other alternative fracture parameter such as the cyclic range of the J-integral, ΔJ.
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These crack growth laws are identified using experimental results from fatigue crack
propagation tests performed on materials.
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The Paris law was the first one proposed in literature correlating the fatigue crack growth rate
with the stress intensity factor range [19]:
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(1)

where Cp and mp are material constants. This relation gives a good description of fatigue crack
propagation in regime II (c.f. Figure 1). The stress ratio effect is an important load parameter
influencing the fatigue crack propagation rate, which is not accounted by the simple Paris
relation. Walker [20] proposed an alternative relation to overcome this limitation of the Paris
model. An extension of the Paris relation to account for crack propagation regime I and stress
ratio effects has been proposed in the literature [21]. In effect, the fatigue crack growth under
the propagation regime I is generally very significant, which requires an accurate definition of
the crack growth in this regime. The crack propagation threshold, ΔKth is itself influenced by
the stress ratio [22]. Forman proposed an extension of Walker model to the propagation regime
III [23]. Hartman and Schijve [24] extended Forman equation to cover the three crack
propagation regimes:

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(2)

This relation results in a sigmoidal shaped curve with vertical asymptotes at Kmax=Kc and

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ΔK=ΔKth. This relation suffers a limitation related to the stress ratio dependency of the ΔKth,
which is not directly considered in the relation. Many other fatigue crack propagation relations

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have been proposed in the literature [25].

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Region I Region II

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-2
10
Kc
da/dN [mm/cycle]

-3
10
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-4
10

-5
10 1 da/dN = C (ΔK)
m
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-6 m
10

-7
10 ΔKth
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Region III
-8
10
Log ΔK
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Figure 1. Fatigue crack propagation regimes.

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A numerical integration of the fatigue crack propagation law can be adopted to compute the
whole fatigue life of a component using the following approximation:

(3)

where Δa is a discrete crack increment which should be kept in a very small value, bellow the
ai=EIFS. The initial crack size ai, is assumed equal to EIFS which is as a material characteristic
that accounts for existing or postulated internal defects. In general, the EIFS may be estimated
by an inverse, back-extrapolation, analysis of the best fatigue life prediction using for such fit
the experimental results of fatigue tests of the notched detail under consideration. Some authors
estimate directly the EIFS parameter based on Kitagawa–Takahashi diagram inflection point
[26,27]:

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(4)

where ΔKth is the stress intensity threshold, Δσf is the fatigue limit and Y is the geometric

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function that allows the computation of the stress intensity factor, as follows:
(5)

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In this paper, a recent model proposed for fatigue crack propagation by Castillo and Fernández-

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Canteli (CCS) [16,17] is applied. This model consists on a new solution for the fatigue crack
propagation based on the assumption that the crack growth follows a cumulative distribution

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function – the Gumbel distribution. The inconvenience of using dimensional parameters in
existing crack propagation models, some of them previously described, is overcome in this new
proposal by means of an appropriate dimensional analysis, carried out on influent variables
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leading to normalized non-dimensional parameters. The identification of the crack growth rate
curve as a cumulative distribution function in which ΔK+ is identified as the normalizing
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variable defined in the interval [0,1] leads to the consideration of log (da/dN) as the random
variable. The proposed model (see details at reference [16,17]) is defined by:
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(6)
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This model depends on four parameters, α, γ, and which may be computed by the
least-squares technique [16,17]. The ‘*’ in the variables of the model means normalized
variables, which can be done, as suggested by the authors, using the following relations:

(7)

where, a is crack length, W is the characteristic length (e.g. specimen length), N is the number
of cycles, N0 is the reference number of cycles, Kmax and Kmin are the maximum and minimum
stress intensity factors, respectively, ΔKth is the threshold intensity factor range, ΔKup is the
limit stress intensity factor range, and finally, Kc is the material characteristic fracture
toughness. This model represents an explicit fatigue cracks growth relation that was supported
by mathematical and physical assumptions. The CCS fatigue crack growth model provides an
analytical expression for the normalized fatigue crack growth rate curve by fitting the
experimental results using the least squares method, c.f. [16]. The normalized crack growth

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curves, a*(N*), can be obtained by solving the differential Eq. (8) that allows obtaining the
normalized parameters, the initial crack size and the stress range, Δσ*:

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(8)

where . The Z function represents a transformation of the function

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defining the geometric crack factor, which is given by:

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(9)
The normalized parameters corresponding to the dimensionless ratios, and Δσ* are given by

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following expressions:

(10.a)
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(10.b)

The decision for selecting the initial crack size in order to proceed with calculation of the
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fatigue life propagation may be supported on probabilistic considerations relative to the

distribution of initial defects and the possible correspondence between the S-N curves and those
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referred to the crack growth a-N.

The key on fatigue modelling using the Fracture Mechanics, and in particular as regards the
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definition of the EIFS parameter, is the selection of the appropriate fatigue crack propagation
laws. Therefore, for generalized elastoplastic conditions, some authors have proposed the use
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of elastoplastic Fracture Mechanics parameters to correlate the fatigue crack growth, as is the
case of the J-Integral, as proposed by Dowling and Begley [28]:

(11)

where da/dN is the fatigue crack growth rate, ΔJ is the range of the cyclic J-integral. This
equation is similar to the Paris relation (fits data in region II), but can be advantageously
applied in situations of large scale yielding.
Rice [29] introduced the initial concept of the J-integral, using the general definition of the
range value of the cyclic J-integral, ΔJ. The ΔJ value is calculated using for the material
behaviour based on the cyclic stress-strain curve taking into account an established hysteresis
loop, which may be described by the Ramberg–Osgood relation [30]:

(12)

where, n’ and K’ are the cyclic strain hardening coefficient and exponent, respectively.

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Another extension of the Paris-type crack growth law was proposed by Alves et al. [15], to
account for fatigue crack propagation regime I with the following expression:

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(13)

where ΔJth is threshold value of the cyclic J-integral.

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In this paper the CCS model will be also extended to cover the cases of elastoplastic loading,
replacing the stress intensity factors on Equations (6)-(8) by the cyclic J-integral counterparts.

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Replacing the stress intensity factor range by the cyclic J-integral range, results the
modification of the CSS crack growth model proposed in this paper. The modified CCS crack

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growth model is therefore given by the following expression:
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(14)
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which depends on four parameters α, γ, ΔJth and ΔJup. The normalized variables suggested by
authors, are then rewritten by the following relations:
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(15)
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where, a, W, N and N0 have the same characteristics that the crack growth model proposed by
Castillo-Canteli-Siegele [16,17], Jmax and Jmin is the maximum and minimum values of the
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cyclic J-integral, respectively, ΔJth is the threshold range value of the cyclic J-integral, ΔJup is
the limit range value of the cyclic J-integral, and finally, Jc is the material characteristic fracture
toughness in J-integral. More precisely, we can write of the following forms:

(16)

where, F() is a cumulative distribution function.

Applying numerical integration on the modified CCS crack growth model results in the number
of cycles to failure of the structural detail:

(17)

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As such, it is possible to estimate the equivalent initial flaw size parameter by an iterative
process. The EIFS is understood herein as a material parameter that results from the fitting of
experimental results from the fatigue tests.

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Thus, the fatigue life prediction is evaluated taking into account the modified CCS crack
growth model proposed in this paper, as well as numerical elastoplastic analyses based on

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stress-strain curve of the material. Therefore, the modified CCS crack growth model supports

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generalized elastoplastic conditions surrounding the crack tip on structural details.

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3. GENERAL PROCEDURE TO PREDICT S-N CURVES BASED ON FRACTURE
MECHANICS
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The procedure proposed to perform fatigue life assessments, based on Fracture Mechanics, for
notched details, can be summarized as follows:
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i) A fatigue crack growth relation must be used to obtain the material constants under
consideration from fatigue crack propagation data. The modified CCS crack growth
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model [16,17], using the cyclic J-Integral is thereby adopted.

ii) Performing elastoplastic stress analyses for the cracked geometry of the structural
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detail under investigation using the finite element method. In these analyses, the
elastoplastic behaviour of the material is modelled using the Ramberg-Osgood model
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[29] aiming at obtaining the cyclic J-integral results for different values. In this paper,
the crack path is advanced, which is acceptable for simple geometries where crack paths
are easily foreseen.
iii) A numerical integration of the modified CCS crack growth equation is next applied,
where the cyclic J-integral is used, taking into account the plastic strains in the region
around the crack-tip.
iv) Estimation of the equivalent initial flaw size parameter using fatigue S-N data of the
structural detail, following the proposed procedure summarized in the Figure 2.
v) As a last step, the fatigue life prediction for the structural component or mechanical
detail is performed (refer to Figure 2).

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Figure 2. General procedure to predict S-N curves based on Fracture Mechanics.

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4. EXPERIMENTAL FATIGUE DATA

The present research is based on experimental data for the P355NL1 pressure vessel steel. The

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fatigue behaviour of this material was evaluated, based on experimental fatigue tests of smooth
specimens as well as fatigue crack propagation tests [18]. In addition, the fatigue data of a

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notched plate is also presented. The material under consideration in this investigation was a

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plate 5mm thick [18]. The P355NL1 steel is intended for pressure vessel applications and is a
normalized fine grain low alloy carbon steel.

4.1. Basic fatigue data of the P355NL1 steel

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The strain-life behaviour of the material was evaluated through fatigue tests of smooth
specimens, carried out under strain control conditions, according to the ASTM E606 standard
[31]. Two series of specimens were tested under distinct strain ratios (Rε=0: 19 specimens;
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Rε=1: 24 specimens). The cyclic Ramberg-Osgood [30] and Morrow [32] strain-life
parameters of this material, for the conjunction of both strain ratios, are summarized in Table 1
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( : cyclic fatigue strength coefficient; b: cyclic fatigue strength exponent; : cyclic fatigue
ductility coefficient; c: cyclic fatigue ductility exponent; K’: cyclic strain hardening coefficient;
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n’: cyclic strain hardening exponent) whereas Table 2 presents the elastic and monotonic
tensile properties (E: Young modulus; ν: Poisson coefficient; fy: yield strength; fu: ultimate
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tensile strength). Figure 3 shows a plot of the experimental strain-life fatigue data, for the two
tested strain ratios. This research adopted the values obtained by combining the results of the
two test series together.

Table 1. Cyclic elastoplastic and strain-life properties of the P355NL1 steel, Rε=‐1&Rε=0.
σ' f b ε' f c K' n'
Material
MPa - - - MPa -
P355NL1 1005.50 -0.1033 0.3678 -0.5475 948.35 0.1533

Table 2. Elastic and tensile properties of the P355NL1 steel.

E ν fu fy
Material
GPa - MPa MPa
P355NL1 205.20 0.275 568.11 418.06

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1.0E0
(Δε/2) = 1005.5/E (2N f )-0.1013 + 0.3678 (2N f ) -0.5475

ε/2 [-]
1.0E-1

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Strain amplitude, DDe/2 1.0E-2

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1.0E-3

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1.0E-4

1.0E-5

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1.0E-6
1.0E+2 1.0E+3 1.0E+4 1.0E+5 1.0E+6 1.0E+7
Reversals to failure, 2N f
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Figure 3. Strain‐life curves for the P355NL1 steel, Rε=‐1&Rε=0.

The fatigue crack propagation tests were performed using Compact Tension specimens with the
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same thickness as the notched plates and showing a width, W=40, following the
recommendations of the ASTM E647 standard [33]. Figure 4 shows the fatigue crack
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propagation data obtained from a total of five specimens tested under constant amplitude
loading, covering three distinct stress ratios, namely Rσ=0, Rσ=0.5 and Rσ=0.7. The analysis of
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the results shows that they are approximately linear in the log-log representation, meaning that
only propagation regime II was covered by the experiments. Propagation regime I, the near
threshold propagation regime, was not covered by the tests.
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Figure 4. Fatigue crack propagation data for the P355NL1 steel.

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4.2. Fatigue data of the notched detail

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A notched detail made of P355NL1 steel was also considered in this investigation. This
notched detail consists of a double side notched rectangular plate. The double side notched

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detail is illustrated in Figure 5 (L1=L2=35mm, L=25mm). This specimen was fatigue tested

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under remote stress controlled conditions, for a stress ratio equal to 0 and respective S-N results
are illustrated in Figure 6 [18]. The results of these fatigue tests are summarized in Table 3.
Specimens 110 and 116 were run-outs, the respective fatigue tests being interrupted at 2.0×106

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cycles. The stress range plotted in Figure 6 corresponds to the nominal stress range applied to
the plate.
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Figure 5. Double side notched rectangular plate (dimensions in mm).

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500
Exp. data

400
Dσ [MPa]

300

Rσ=0.0
200
1.0E3 1.0E4 1.0E5 1.0E6 1.0E7
Cycles to failure, Nf

Figure 6. S-N fatigue data of the notched plate.

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Table 3. S-N results of the notched plate made of P355NL1 steel.

f Ds Nf

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Specimen Rσ
Hz MPa cycles
100 10 440 0 192

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101 10 380 0 9785
102 10 365 0 12336
103 10 330 0 30270

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104 10 280 0 100743
105 10 280 0 105230
106 10 280 0 118254

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107 10 400 0 4221
108 10 400 0 6619
109 10 400 0 7201
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110 15 200 0 2000000 ()
111 10 330 0 19157
112 10 330 0 27780
113 5 420 0 1009
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114 15 250 0 372701

115 15 250 0 385760
116 15 215 0 2000000 ()
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117 10 400 0 6632

118 5 330 0 25217
119 5 330 0 23215
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120 5 420 0 969

121 5 420 0 521
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5. FATIGUE LIFE EVALUATION OF THE NOTCHED DETAIL: APPLICATION OF

THE GENERAL PROCEDURE

Fatigue life evaluation of the notched detail was based on the proposed general procedure
depicted in Figure 2. The general procedure to predict the fatigue life of the notched plate is
supported by an extension of the CCS crack growth model proposed by Castillo-Canteli-
Siegele [16,17], using the cyclic J-integral. The resulting modified CCS crack growth model
proposed in this paper is able to represent all regions of the propagation phase. This crack
growth model is supported by the crack propagation data resulting from experimental tests. The
values of cyclic J-integral for different values of stress ranges, Δσ, and crack lengths, a, were
obtained using an elastoplastic stress analysis based on finite element method. The proposed

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general procedure was supported by the numerical integration of the modified CCS crack
growth model, which is based on the equivalent initial flaw size parameter allows the fatigue
life prediction of the notched detail under consideration.

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5.1. Finite element analysis of the notched plate

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The notched plate was modelled using the finite element method which was applied to perform
elastoplastic stress analyses aiming at computing the range of the cyclic J-integral. A bi-

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dimensional finite element model was used to simulate the plate under consideration using
ANSYS® 12.0 code. In the analysis, plane stress 6-noded quadratic triangular elements
(PLANE 181) were used due to the limited specimen thickness (see Figure 7) [14]. This finite
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element model was built with 14872 elements and 30201 nodes. The J2 plasticity constitutive
model, based on multilinear kinematic hardening, was applied. Figure 8 represents the fitting of
the plasticity model to the Ramberg-Osgood experimentally based curve [14]. A parametric
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model was built using the APDL language. Only half of the geometry of the plate is modelled,
taking into account the existing symmetry plane. Experiments have shown that cracks started at
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one side notch root and propagated asymmetrically in the plate. Therefore the mesh was
provided with a crack on the left notch. The ranges of the cyclic J-integral were computed
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based on an elastoplastic finite element analysis and J-integral computation capabilities

available in ANSYS. The stress fields along the y (load) direction, obtained for the notched
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plate using the elastoplastic finite element analysis, are illustrated in Figure 9, for a crack size
a=2.5mm, an applied stress range of Δσ=250MPa, and a stress R-ratio, Rσ=0.0. At the end of
the unloading reversal one realize compressive stresses at the vicinity of the crack tip which are
justified by a plastic region at that location developed during the prior tensile reversal. These
compressive residual stresses are responsible for a degree of crack closure level. Figure 10
represents the range values of the cyclic J-Integral as a function of the nominal stress range for
three selected values of the crack lengths starting at the side notch, a=0.625mm, a=2.5mm and
a=6.25mm.

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Figure 7. Finite element mesh of the rectangular notched plate with a side crack (1/2 geometry).

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600
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500
Stress [MPa]

400
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300

200

Ra mberg-Os good
100
FEM - Mul til i nea r
0
0.00E+00 1.00E-02 2.00E-02 3.00E-02 4.00E-02 5.00E-02
Strain [-]

Figure 8. Cyclic stress-strain relation obtained for the P355NL1 steel.

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a) Elastoplastic direct stress field in the y direction, σy, in MPa, at the end of the first loading

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reversal.
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b) Elastoplastic direct stress field in the y direction, σy, in MPa, at the end of the first
unloading reversal.
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Figure 9. Stress fields, along the y (load) direction, obtained for the notched plate of P355NL1
steel, resulting from elastoplastic finite element analysis (Δσ=250MPa, Rσ=0.0 and a=2.5mm).

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100
Elastoplastic Analysis
80 Linear-elastic analysis
a=0.625mm

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ΔJ [N/mm]
60

40

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20

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0
200 250 300 350 400 450 500

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Nominal stress range, Δσ [MPa]
a)
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100
Elastoplastic Analysis
Linear-elastic analysis
80
a=2.5mm
ΔJ [N/mm]

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60

40
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20
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0
200 250 300 350 400 450 500
Nominal stress range, Δσ [MPa]
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b)
100
Elastoplastic Analysis
Linear-elastic analysis
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a=6.25mm
ΔJ [N/mm]

60

40

20

0
200 250 300 350 400 450 500
Nominal stress range, Δσ [MPa]
c)
Figure 10. Values of range of the cyclic J-Integral as a function of nominal stress range for the
notched plate, Rσ=0: a) a=0.625mm; b) a=2.5mm; c) a=6.25mm.

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5.2. Application and discussion

In order to proceed with the fatigue life prediction of the notched plate it is necessary to

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determine the threshold and maximum values of J-integral based on crack propagation tests,
since they are parameters of the modified CCS crack growth model followed in this paper.

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Concerning the estimation of the threshold value of J-integral, it was evaluated from the stress

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intensity threshold, ΔKth, which was estimated using the following linear relation [22]:
(18)
-1.5

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where the value 152 N.mm corresponds to the propagation threshold for Rσ=0. This value is
very consistent with the threshold value of the stress intensity range for the mild steel with
yield strength of 366 MPa point out in reference [22], which is similar for the P355NL1 steel.
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The threshold value of the cyclic J-integral, ΔJth, was obtained based on stress intensity
threshold, ΔKth, using the following expression:
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(19)

where, E is the Young’s modulus. Since the thickness of the CT specimens and the notched
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plates are the same, these maximum values of cyclic J-integral observed during the fatigue
crack propagation tests are a good estimate of the material toughness. Due to the lack of data
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also in regime III an estimated value for ΔJmax = ΔJup = 8 N/mm was adopted. The threshold
and maximum values of cyclic J-integral were used to define de minimum and maximum crack
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sizes in the simulations, respectively. The minimum crack size in the simulations corresponds
to the equivalent initial flaw size for the best fatigue life prediction.
The parameters of the modified CCS crack growth model are shown in Table 3 for Rσ=0, and
are used for the numerical integration of the modified CCS crack propagation model. The
modified CCS fatigue crack growth model proposed in this study is depicted in Figure 11 for
the stress R-ratios, 0, 0.5 and 0.7, tested experimentally.

Table 3. Modified CCS crack growth model constants.

Fitting value, Adopted value,
Rσ N0 α γ log(ΔJ*th) log(ΔJ*up)
ΔJth [N/mm] ΔJup [N/mm]

0.0 0.11 8.00 1000 -7,102355 2,520205 -4,509860006 -0,223143551

0.5 0.06 8.00 1000 -7,218035 2,90247 -5,11599581 -0,223143551
0.7 0.04 8.00 1000 -7,44061 2,88985 -5,521460918 -0,223143551

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b)
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c)
Figure 11. Fatigue crack growth data correlated with the modified CCS fatigue crack growth
model for various stress ratios: a) Rσ =0; b) Rσ=0.5; c) Rσ=0.7.

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In order to determine the fatigue life prediction of the notched plate under consideration, the
proposed general procedure shown in Figure 2 was applied. Table 3 and Figure 11 presents the
CCS crack growth model constants and experimental fitting, respectively. The numerical

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integration of the modified CCS crack growth model (c.f. Section 3) using the EIFS parameter
as adjustment variable allows the estimation of the fatigue life prediction.

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Figure 12 shows the best prediction of the S-N curve for the notched plate, for a stress ratio

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equal to 0. It is clear that the general procedure produced very satisfactory correlation of the
experimental fatigue data for the notched plate of P355NL1 steel. Based on the proposed
general procedure used in this study, the EIFS parameter was assumed equal to 63.63μm for the

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best fatigue life prediction. The crack increment used in the numerical integration was 1/10 of
the EIFS. The modified CCS crack growth model using the cyclic J-integral approach was able
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to produce a satisfactory prediction of the limit and propagation regions.

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Series5
Modified CCS & EIFS models
Stress range, Dσ [MPa]

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400
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300
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Rσ = 0.0
EIFS =a0 = 63.63μm

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1.0E3 1.0E4 1.0E5 1.0E6 1.0E7
Cycles, N

Figure 12. Fatigue life prediction using a Fracture Mechanics based method and the EIFS.

The proposed approach can potentially be further explored to estimate a distribution of the
EIFS in the material which is consistent with the scatter observed in the S-N data. However,
scatter of fatigue crack propagation properties of the steel should be also addressed which
requires a probabilistic approach for the fatigue crack propagation itself.

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6. CONCLUDING REMARKS

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A general procedure for the fatigue life prediction using Fracture Mechanics supported by the
modified CCS fatigue crack growth model was assessed in this paper, taking into account the

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experimental fatigue data available for a double notched plate made of P355NL1 steel.

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The total fatigue life prediction was modelled assuming a crack propagation process, from an
equivalent initial flaw size, EIFS. Experimental fatigue crack growth rates were used to

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estimate the modified crack growth model constants. The modified CCS crack growth model
proposed in this paper using the cyclic J-integral parameter allows generalized elastoplastic
conditions of the structural detail under consideration. The modified CCS crack growth model
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resulting from the original model proposed by Castillo-Canteli-Siegele covers all regions of the
fatigue crack propagation regime.
The crack propagation threshold value was assumed in this paper as being consistent with data
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published in the literature for similar materials. The proposed approach was applied to
experimental fatigue tests of a double notched plate made of P355NL1 steel, whose S-N data is
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available in the literature. S-N predictions showed satisfactory agreement with experimental
data. The EIFS concept supported by the cyclic J-integral approach using finite element
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analysis was able to account for stress R-ratio, equal 0, thus describing the best fatigue life
prediction for the notched plate made in P355NL1 steel. The EIFS parameter was estimated as
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63.63 μm.
Future development of the proposed approach should account for stress ratio effects as well as
crack closure effects, which could be included in the fatigue crack propagation model.

ACKNOWLEDGEMENTS

The authors acknowledge the Portuguese Science Foundation (FCT) for the financial support
through the post-doctoral grant SFRH/BPD/107825/2015. Authors gratefully acknowledge the
funding of SciTech - Science and Technology for Competitive and Sustainable Industries,
R&D project cofinanced by Programa Operacional Regional do Norte ("NORTE2020"),
through Fundo Europeu de Desenvolvimento Regional (FEDER).

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Highlights
 A procedure for fatigue life prediction of structural details/mechanical
components proposed.
 A fatigue approach based on Fracture Mechanics is followed.

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 Equivalent initial flaw size concept is used and identified using inverse analysis.
 A generalisation of the normalized crack growth model based on Gumbel
distribution is proposed.

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 Cyclic J-integral is introduced to allow generalized elastoplastic conditions.
 S-N data of notched plate of P355NL1 steel satisfactorily correlated using
simulated results.

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